Aluminum alloys having a pre-determined electrical conductivity

Abstract

An aluminum alloy and a method of making the aluminum alloy comprised of pure aluminum and a casting aluminum. The pure aluminum and casting aluminum are alloyed in appropriate proportions such that the aluminum alloy includes a desired electrical conductivity in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) International Annealed Copper Standard (IACS). Embodiments of the aluminum alloy include a combination of A100 aluminum, and A356 aluminum, A357 aluminum, A360 aluminum, and/or A380 aluminum. The aluminum alloy is made for use in applications where an electrical conductivity less than copper is desired (e.g., wiring cables, cast rotors for induction motors, wound rotors for induction motors, and the like).

1 . A castable aluminum alloy, comprising: 
 A100 aluminum alloyed with at least one of A356 aluminum, A357 aluminum, A360 aluminum, and A380 aluminum, wherein the castable aluminum alloy comprises a pre-determined electrical conductivity.    
   
   
       2 . The castable aluminum alloy of  claim 1 , wherein the castable aluminum alloy is comprised of said A100 aluminum in the range of about ten percent to about 90 percent.  
   
   
       3 . The castable aluminum alloy of  claim 2 , wherein the castable aluminum alloy is comprised of said at least one of A356 aluminum, A357 aluminum, A360 aluminum, and A380 aluminum in the range of about ten percent (10%) to about ninety percent (90%).  
   
   
       4 . The castable aluminum alloy of  claim 3 , wherein said pre-determined electrical conductivity is in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) International Annealed Copper Standard (IACS).  
   
   
       5 . The castable aluminum alloy of  claim 4 , wherein the castable aluminum alloy comprises said A356 aluminum, and said pre-determined electrical conductivity is in the range of about forty percent (40%) to about fifty-four percent (54%) IACS.  
   
   
       6 . The castable aluminum alloy of  claim 5 , wherein the castable aluminum alloy is comprised of about sixty-five percent (65%) A100 aluminum by weight and about thirty-five percent (35%) A356 aluminum by weight.  
   
   
       7 . The castable aluminum alloy of  claim 6 , wherein the pre-determined electrical conductivity is about forty-seven percent (47%) IACS.  
   
   
       8 . The castable aluminum alloy of  claim 4 , wherein the castable aluminum alloy comprises said A357 aluminum, and said pre-determined electrical conductivity is in the range of about forty percent (40%) to about fifty-four percent (54%) IACS.  
   
   
       9 . The castable aluminum alloy of  claim 4 , wherein the castable aluminum alloy comprises said A360 aluminum, and said pre-determined electrical conductivity is in the range of about thirty-seven percent (37%) to about fifty-four percent (54%) IACS.  
   
   
       10 . The castable aluminum alloy of  claim 4 , wherein the castable aluminum alloy comprises said A380 aluminum, and said pre-determined electrical conductivity is in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) IACS.  
   
   
       11 . A method of making a castable aluminum alloy with a pre-determined conductivity comprising the steps of: 
 alloying A100 aluminum with at least one casting aluminum to form the castable aluminum alloy, 
 wherein said alloying step comprises the step of alloying said A100 aluminum with said at least one casting aluminum in proportions such that the castable aluminum alloy comprises an electrical conductivity in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) International Annealed Copper Standard (IACS).  
   
   
   
       12 . The method of  claim 11 , wherein said alloying step further comprises the step of alloying said A100 aluminum with at least one of A356 aluminum, A357 aluminum, A360 aluminum, and A380 aluminum.  
   
   
       13 . The method of  claim 12 , wherein said alloying step comprises the step of alloying said A100 aluminum with said A356 aluminum in proportions such that said electrical conductivity is in the range of about forty percent (40%) to about fifty-four percent (54%) IACS.  
   
   
       14 . The method of  claim 12 , wherein said alloying step comprises the step of alloying said A100 aluminum with said A357 aluminum in proportions such that said electrical conductivity is in the range of about forty percent (40%) to about fifty-four percent (54%) IACS.  
   
   
       15 . The method of  claim 12 , wherein said alloying step comprises the step of alloying said A100 aluminum with said A360 aluminum in proportions such that said electrical conductivity is in the range of about thirty-seven percent (37%) to about fifty-four percent (54%) IACS.  
   
   
       16 . The method of  claim 12 , wherein said alloying step comprises the step of alloying said A100 aluminum with said A380 aluminum in proportions such that said electrical conductivity is in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) IACS.  
   
   
       17 . The method of  claim 12 , wherein said alloying step further comprises the step of alloying said A100 aluminum with each of said A356 aluminum, said A357 aluminum, said A360 aluminum, and said A380 aluminum.  
   
   
       18 . An induction rotor, comprising: 
 a substantially cylindrical body, said body comprising a first side surface and a second side surface;    a plurality of conductor bars coupled to said body; and    a plurality of end rings coupled to said body; and 
 wherein at least a portion of the induction rotor is comprised of an aluminum alloy with a pre-determined electrical conductivity, said aluminum alloy comprising A100 aluminum and a casting aluminum, wherein said casting aluminum comprises at least one of A356 aluminum, A357 aluminum, A360 aluminum, and A380 aluminum, and wherein said pre-determined electrical conductivity is in the range of about twenty-seven percent (27%) to about fifty-four percent (54%) International Annealed Copper Standard (IACS).  
   
   
   
       19 . The induction rotor of  claim 18 , wherein said casting aluminum is A356 aluminum and said pre-determined electrical conductivity is in the range of about forty percent (40%) to about fifty-four percent (54%) IACS.  
   
   
       20 . The induction rotor of  claim 19 , wherein said aluminum alloy is comprised of about sixty-five percent (65%) A100 aluminum and about thirty-five percent (35%) A356 aluminum, and wherein said pre-determined electrical conductivity is about forty-seven percent (47%) IACS.